Shared Flux Inductor Array for Fuel Cell Boost Converter
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Solution Overview
Problem
Current DC/DC converters in fuel cell systems for vehicles are large, heavy, costly, and inefficient due to the use of traditional inductor arrays with wide gaps that lead to fringing flux and eddy current losses, which are exacerbated by the need for high power and compact design.
Innovation Solution
The inductor array design features adjacent inductors sharing a core piece and flux path, utilizing a hybrid core with amorphous alloy for U-shaped end pieces and stamped metal sheet center pieces to reduce size, weight, and losses, while maintaining magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional inductor arrays with wide gaps are used, then magnetic flux can be established, but fringing flux and eddy current losses increase leading to reduced efficiency
Solution Approach 1:
Adjacent inductors share common core pieces and flux return paths, merging previously separate magnetic circuits. This reduces the number of individual core components and eliminates unnecessary gaps between inductors, thereby reducing eddy current losses and fringing flux while maintaining the required magnetic performance for each inductor.
Solution Approach 2:
The shared core pieces serve multiple functions: they act as magnetic path for adjacent inductors simultaneously, provide structural support, and enable flux cancellation effects. This multi-functionality reduces overall device complexity while improving efficiency by eliminating redundant components.
2Power
If high power fuel cell systems are implemented, then vehicle power demand is met, but the size and weight of DC/DC converter increase
Solution Approach 1:
Multiple inductors share common magnetic core pieces and flux return paths, reducing the total amount of magnetic material required. This merging approach maintains the high power handling capability through parallel inductor configurations while significantly reducing the overall weight and size of the DC/DC converter.
Solution Approach 2:
The patent employs hybrid core constructions combining different magnetic materials optimized for specific functions, allowing high power operation with reduced material mass. The composite approach enables efficient magnetic flux management at high power levels without proportionally increasing converter weight.
3Volume of moving object
If compact DC/DC converter design is pursued, then vehicle integration space is reduced, but magnetic flux path requirements become more difficult to satisfy
Solution Approach 1:
Adjacent inductors share common core pieces and flux return paths, allowing compact arrangement of multiple inductors in reduced space. The shared magnetic paths are designed to maintain proper flux density and distribution, ensuring reliable magnetic performance despite the compact configuration.
Solution Approach 2:
The patent utilizes three-dimensional core configurations where flux paths extend in multiple spatial dimensions. This allows compact planar arrangement while maintaining adequate magnetic path lengths and cross-sectional areas for reliable high-power operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces the size and weight of the inductor array by 30% and minimizes electrical losses, enhancing efficiency and cost-effectiveness for high-power applications.
Implementation Method 1
a current propagating through the windings generates a magnetic flux in the core and the gap
Implementation Method 2
adjacent inductors have a shared core piece and thus a shared flux path
Data Source
AI summary
An inductor array that includes a plurality of inductors where adjacent inductors share a core piece and thus a flux path to reduce the size and weight of the array. In one embodiment, the shared core pieces are formed as back-to-back U-shaped members defining an indented region at the center of the core piece. In another embodiment, a plurality of small block-shaped center core pieces in each inductor defines a plurality of gaps therebetween.